80442833
Revision F
October 2012
HL Series Desiccant Dryer
MODELS 90-5000
Operator’s Manual
EN
Operator’s Manual
ES
Manual Del Operador
Manuel De L’opérateur
Manual do Operador
FR
PT
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1.0 CONTENTS
CONTENTS
PAGE
1.0
CONTENTS
3
2.0
INTRODUCTION
4
3.0
WARRANTY
4
4.0
HEATLESS DRYER NOMENCLATURE 4
5.0
RECEIVING AND INSPECTION
5
5.1
INSPECTION
5
5.2
UNPACKING AND HANDLING
5
6.0
SAFETY AND OPERATION
PRECAUTIONS
5
7.0
PRINCIPLES OF OPERATION
6
7.1
INTRODUCTION
6
7.2
DRYING CYCLE
6
7.3
REGENERATION CYCLE
6
7.4
SETTING THE REGENERATION AIR FLOW 6
7.5
TOWER REPRESSURIZATION
6
7.6
VALVES
7
7.7
TIMING SEQUENCE
7
7.7.1 TIMING CYCLE FOR -40°F DEW POINT
DRYERS
7
7.7.2 TIMING CYCLE FOR -100°F DEW POINT
DRYERS
7
7.8
CONTROLS
7
7.8.1 BASIC USER INTERFACE
7
7.8.2 MICROPROCESSOR CONTROL
DISPLAY PARAMETERS
9
7.8.3 ALARMS AND THEIR FUNCTIONS
9
7.8.4 RESTART MODES AND OPERATING
DISPLAYS
11
7.8.4.1 RESTART MODE
11
7.8.4.2 OPERATION HOURS
11
8.0
ALARMS AND INDICATORS
12
8.1
MOISTURE INDICATOR
12
8.2
FAILURE TO SHIFT ALARM (OPTIONAL) 12
8.3
ENERGY MANAGEMENT SYSTEM
(EMS) - (OPTIONAL)
12
8.4
HIGH DEW POINT ALARM (INCLUDED
WITH EMS)
12
8.5
COMPRESSOR INTERLOCK
12
9.0
INSTALLATION AND INITIAL
START-UP
13
9.1
APPLICATION AND CHECK ANALYSIS 13
9.2
LOCATING AND MOUNTING
13
2
CONTENTS
PAGE
9.3
PIPING
13
9.4
FILTRATION
13
9.5
DEW POINT TRANSMITTER
INSTALLATION (OPTIONAL)
13
9.6
ELECTRICAL CONNECTION
14
9.7
DESICCANT LEVEL VERIFICATION
14
9.8
START-UP
14
9.9
SHUT-DOWN SEQUENCE
15
10.0 TECHNICIAN MODE
16
10.1
ENTERING TECHNICIAN MODE
16
10.2
DEW POINT ADJUSTER
(-40 °F DRYERS ONLY)
16
10.4
RESTART MODE
17
10.5
PURGE FLOW ADJUSTER
18
10.6
COMPRESSOR INTERLOCK
18
10.7
HIGH DEW POINT ALARM
(INCLUDED WITH EMS OPTION)
18
10.7.1 DESCRIPTION AND ACTIVATION
18
10.7.2 SETPOINT ADJUSTMENT
19
11.1
SCHEDULED MAINTENANCE
20
11.2
PRE-FILTERS AND POST-FILTERS
20
11.2.1 THREADED FILTERS:
20
11.2.2 FLANGED FILTERS:
21
11.3
PILOT AIR CONTROL NO-LOSS
DRAIN VALVES
21
11.4
MUFFLER CHANGEOUT PROCEDURE 21
11.5
PURGE AND SWITCHING
DIAPHRAGM VALVES
(HL90 - HL 2700)
21
11.6
PILOT OPERATED ACTUATOR
(HL3300 - HL5000)
21
11.7
OUTLET CHECK VALVES
21
11.8
DESICCANT CHANGEOUT PROCEDURE 22
12.0 TROUBLESHOOTING
24
13.0 PURGE CHARTS
25
14.0 GENERAL ARRANGEMENT
28
15.0 WIRING DIAGRAM
39
16.0 FLOW DIAGRAM
40
17.0 REPLACEMENT PARTS
42
18.0
ENGINEERING SPECIFICATIONS
47
HL Series Desiccant Dryer Models 90-5000
ingersollrandproducts.com
2.0 INTRODUCTION
The Ingersoll Rand Heatless Desiccant Dryers are designed
to adsorb moisture from compressed air. The dryers are
constructed with two towers, each containing desiccant
beads, that alternate between online (drying) and offline
(regenerating) modes, yielding a continuous stream of dry
air at the dryer’s outlet.
During normal operation, wet air passes through the on line
tower and water vapor from the air is adsorbed (collected)
on the desiccant beads. While air is being adsorbed in
the online tower, the moisture on the desiccant in the
offline tower is removed by a process called desorption
(regeneration). After an initial rapid depressurization, a
portion of dried air from the online tower passes over the
desiccant bed and carries the moisture off the bed and out
the dryer’s exhaust.
The continuous, alternating process of adsorption and
desorption is controlled using a timer that switches the
towers in a specific timed sequence. Very dry compressed air
dew points are achieved through the continuous switching
and operation of this dryer. Ingersoll Rand offers dryers to
provide either -40°F or -100°F pressure dew point outlet air.
3.0 WARRANTY
The Company warrants that the equipment manufactured by
it and delivered hereunder will be free of defects in material
and workmanship for a period of twelve months from the
date of placing the Equipment in operation or eighteen
months from the date of shipment from the factory,
whichever shall first occur. The Purchaser shall be obligated
to promptly report any failure to conform to this warranty,
in writing to the Company in said period, whereupon the
Company shall, at its option, correct such nonconformity, by
suitable repair to such equipment or, furnish a replacement
part F.O.B. point of shipment, provided the Purchaser has
stored, installed, maintained and operated such Equipment
in accordance with good industry practices and has
complied with specific recommendations of the Company.
Accessories or equipment furnished by the Company, but
manufactured by others, shall carry whatever warranty the
manufacturers have conveyed to the Company and which
can be passed on to the Purchaser. The Company shall
not be liable for any repairs, replacements, or adjustments
to the Equipment or any costs of labour performed by
the Purchaser or others without Company’s prior written
approval.
The effects of corrosion, erosion and normal wear and tear
are specifically excluded. Performance warranties are limited
to those specifically stated within the Company’s proposal.
Unless responsibility for meeting such performance
warranties are limited to specified tests, the Company’s
obligation shall be to correct in the manner and for the
period of time provided above.
THE COMPANY MAKES NO OTHER WARRANTY OR
REPRESENTATION OF ANY KIND WHATSOEVER, EXPRESSED
OR IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED
WARRANTIES OF MERCHANT ABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, ARE HERBY DISCLAIMED.
Correction by the Company of non conformities whether
patent or latent, in the manner and for the period of time
provided above, shall constitute fulfilment of all liabilities of
the Company for such non conformities whether based on
contract, warranty negligence, indemnity, strict liability or
otherwise with respect to or arising out of such Equipment.
The Purchaser shall not operate Equipment which is
considered to be defective, without first notifying the
Company in writing of its intention to do so. Any such use of
Equipment will be at Purchaser’s sole risk and liability.
Note that this is Ingersoll Rand standard warranty. Any
warranty in force at the time of purchase of the equipment
or negotiated as part of the purchase order may take precedence over this warranty.
4.0 HEATLESS DRYER NOMENCLATURE
PREFIX
NOMINAL*
FLOW (m3/hr)
HL
90-5000
POWER /
DEW POINT
NEMA/ MAWP
ELECTRICAL
OPTION
ELECTRICAL
OPTION
1 = 115 / -40
H = NEMA 4 /
0 = Standard
0 = Standard
B = 115/ -100
150 psig MAWP F = EMS for
3=200-1-50/-40
Heatless Dryers
E=220-1-50/-100
MECHANICAL
OPTION
FILTERS
A = Downstream A = Filters Attached
Purge (Standard)
L = Filters Loose
* Nominal Flows indicated are for 100°F inlet temperature, 100°F ambient temperature and 100 psig compressed air pressure.
NOTICE
Nomenclature shown above represents standard price sheet options. Other options are available, refer to
nomenclature insert specific to your dryer for details.
HL Series Desiccant Dryer Models 90-5000
ingersollrandproducts.com
3
5.0 RECEIVING AND INSPECTION
5.1
INSPECTION
5.2
Upon receiving your Ingersoll Rand air dryer, please inspect
the unit closely. If rough handling has been detected, please
note it on your delivery receipt, especially if the dryer will not
be immediately uncrated. Obtaining the delivery person’s
signed agreement to any noted damages will facilitate any
insurance claims
UNPACKING AND HANDLING
WARNING
Under no circumstances should any person attempt
to lift heavy objects without proper lifting equipment
(i.e., crane, hoist, slings or fork truck). Lifting any unit
without proper lifting equipment, can cause serious
injury.
Refer to labels on the dryer for the appropriate means for
lifting or moving the dryer. When lifting the dryer, ensure that
no stress is applied to the piping or valving. Refer to Section
9.2 for locating and mounting of dryer.
6.0 SAFETY AND OPERATION PRECAUTIONS
Because an air dryer is pressurized and contains rotating
parts, the same precautions should be observed as with
any piece of machinery of this type where carelessness in
operation or maintenance could be hazardous to personnel.
In addition to obvious safety rules that should be followed
with this type of machinery, safety precautions as listed
below must be observed:
1. Only qualified personnel shall be permitted to adjust,
perform maintenance or repair this air dryer.
2. Read all instructions completely before operating
unit.
3. Pull main electrical disconnect switch and disconnect
any separate control lines, if used, before attempting
to work or perform maintenance on the unit.
4. Do not attempt to service any part while machine is in
an operational mode.
5. Do not attempt to remove any parts without first
relieving the entire air system of pressure.
6. Do not operate the dryer at pressures in excess of its
rating.
7. Do not operate the dryer without guards, shields and
screen in place.
8. Inspect unit daily to observe and correct any unsafe
operating conditions.
4
OSHA
Heading Descriptions
WARNING
“Warning” is used to indicate a hazardous situation
which has some probability of death or severe injury.
Warning should not be considered for property
damage accidents unless personal injury risk is present.
ATTENTION
“Caution” is used to indicate a hazardous situation
which may result in minor or moderate injury.
NOTICE
“Notice” is used to indicate a statement of company
policy as the message relates directly or indirectly
to the safety of personnel or protection of property.
Notice should not be associated directly with a hazard
or hazardous situation and must not be used in place
of “Danger,” “Warning,” or “Caution.
NOTICE
The user of any air dryer manufactured by Ingersoll
Rand, is hereby warned that failure to follow the
above Safety and Operation Precautions may result
in personal injury or equipment damage. However,
Ingersoll Rand does not state as fact, nor does it
mean to imply, that the preceding list of Safety and
Operating Precautions is all inclusive, and further, that
the observance of this list will prevent all personal
injury or equipment damage.
HL Series Desiccant Dryer Models 90-5000
ingersollrandproducts.com
7.0 PRINCIPLES OF OPERATION
7.1
INTRODUCTION
As described in Section 2, water vapor is removed from
compressed air by diverting air flow alternately between two
towers filled with desiccant. While one tower processes the
compressed air stream, adsorbing water vapor, the opposite
tower is regenerated by desorbing the water vapor and
venting it to atmosphere. Refer to the Flow Diagram for a
visual representation of the drying and regenerating cycles.
7.2
DRYING CYCLE
Saturated compressed air enters the dryer and is diverted
to the appropriate tower by the Inlet Flow Valves. Referring
to the Flow Diagram (Section 16.0), the Left Inlet Flow Valve
is actuated to a closed position to prevent air flow from
entering the regenerating tower. Simultaneously, the Right
Inlet Flow Valve is actuated to an open position, allowing
air flow to the right hand tower. During this time, the
Right Tower Purge Valve is actuated to a closed position,
preventing the compressed air from venting to atmosphere.
As the compressed air flows through the desiccant material
at pressure, removal of water vapor from the air stream
begins to occur through adsorption. In the adsorption
process, the desiccant material draws water vapor out of the
compressed air and “holds” it until the right tower drying
cycle is complete. Compressed air flows out of the tower for
delivery to the process use. The Outlet Flow Check Valves
provide air flow diversion to the outlet air connection of the
dryer. The Right Outlet Flow Check Valve allows air flow
through to the outlet connection of the dryer while The Left
Outlet Flow Check Valve checks off to prevent flow back to
the regenerating tower.
7.3
REGENERATION CYCLE
Heatless dryers are equipped with the ability to use air from
a downstream source to purge the regenerating towers.
This feature is useful for applications with downstream (dry)
storage tanks, as pulling air from a downstream source can
minimize cycling of the air compressor.
7.4
SETTING THE REGENERATION AIR FLOW
Proper setting of the purge is necessary to achieve proper
dryer performance. Setting the purge flow too high will
waste compressed air and if set too low, the dryer will not
achieve proper dew point performance.
The purge adjustment manifold consists of the Purge
Adjustment Valve, the Purge Pressure Gauge and the Purge
Orifice. Manually adjust the Purge Adjustment Valve until
the gauge reading on the purge pressure gauge matches
the Purge Pressure Gauge setting listed on the laminated tag
affixed to the Orifice Plate Assembly.
NOTICE
On dryers equipped with the optional EMS feature,
the purge valve MUST be set to the factory set point to
ensure proper operation of this feature.
7.5
TOWER REPRESSURIZATION
Upon completion of tower regeneration, and prior to the
Inlet Flow Valves changing position to switch towers, the
regenerated tower must be repressurized.
NOTICE
Failure to re-pressurize prior to tower switchover will
result in shocking the desiccant material and cause
premature desiccant dusting.
Previously adsorbed moisture, removed from the process
stream, gets stripped or desorbed from the desiccant
material in the regeneration process. The first stage of
regeneration is tower depressurization. After the Inlet
Flow Valves are switched to divert air flow away from the
regenerating tower, the appropriate Purge Valve will be
opened and the tower will be depressurized. Through rapid
depressurization, a significant portion of the previously
adsorbed water vapor is stripped off of the desiccant
material and exhausted to atmosphere.
Repressurization is accomplished by closing the appropriate
Purge Valve. Closing the Purge Valve allows the regeneration
air to begin to pressurize the tower. In addition to the
regeneration air, the Repressurization Valve, (standard on
-100°F dew point and high pressure dryers) opens allowing
some additional air from the outlet of the dryer to ensure
adequate pressurization. During normal tower regeneration,
the Repressurization Valve is held closed so that the only
source of air for regeneration passes through the purge
adjustment assembly.
The second stage of regeneration uses a portion of the
dry, compressed air, expanded to atmospheric pressure to
complete the desorption process. As shown on the FLow
Diagram, the compressed air exits the drying tower and a
portion of the air flows through the Purge Adjustment Valve
and the Purge Orifice. Once the air has passed through
Purge Orifice, it expands to atmospheric pressure and
continues the regeneration process. Desorption occurs as
the desiccant releases water vapor into the regeneration air
and is exhausted through the Purge Muffler.
7.6
VALVES
Solenoid control valves are used to actuate the Flow Valves,
Purge Valves and the optional Repressurization Valve
on Heatless Dryers. The Inlet Flow Valves and optional
Repressurization Valve are normally open valves, while the
Purge Valves are connected as normally closed valves. This
arrangement permits air to flow through the dryer during
periods of loss of power.
Outlet Check Valves are single direction check valves that will
HL Series Desiccant Dryer Models 90-5000
ingersollrandproducts.com
5
7.0 PRINCIPLES OF OPERATION
allow flow in the direction shown on the Flow Diagram, but
not allow flow in the opposite direction.
7.7
TIMING SEQUENCE
All timing functions are controlled by the Microprocessor
Controller. Timing for HL Series dryers is as follows:
7.7.1
TIMING CYCLE FOR -40°F DEW POINT DRYERS
The standard timing cycle for -40°F operation
switches the Inlet Flow Valve position every five
minutes which alternates the drying tower. At
the same time as a tower Inlet Valve opens,
the appropriate tower Purge Valve opens to
depressurize the regenerating tower. Tower
regeneration occurs for 4 minutes and 15 seconds,
at which time the Purge Valve closes to initiate
repressurization.
7.7.2
TIMING CYCLE FOR -100°F DEW POINT DRYERS
The standard timing cycle for -100°F operation
switches the Inlet Flow Valve position every 2
minutes which alternates the drying tower. At
the same time as a tower Inlet Valve opens,
the appropriate tower Purge Valve opens to
depressurize the regenerating tower. Tower
regeneration occurs for 1 minute and 50 seconds,
at which time the Purge Valve closes to initiate
repressurization. The Repressurization Valve opens
to assist tower repressurization for the last 10
seconds prior to Inlet Flow Valve switching.
7.8
CONTROLS
The Microprocessor Controller controls all pneumatic valve
operation and dryer functions as well as communicates
dryer alarms. The Microprocessor Controller stores the last 20
alarm conditions, displaying the alarm and the time and date
the alarm occurred. This useful feature can greatly facilitate
troubleshooting of the dryer.
The Microprocessor Controller features three levels of
access. The default level CUSTOMER MODE permits viewing
of various drying parameters. A protected TECHNICIAN
MODE permits access to and manipulation of additional
parameters. A password protected FACTORY MODE is also
included for use with Ingersoll Rand Service Personnel for
troubleshooting the dryer.
7.8.1
BASIC USER INTERFACE
The Microprocessor Control display provides
the user with the operating parameters and their
corresponding values. When power is supplied to
the dryer, the Microprocessor Control will illuminate
and default to the “Standby” mode, displaying the
“Press ON” prompt.
The following illustration summarizes the keypad
functions.
FIGURE 1 - MICROPROCESSOR CONTROLLER
6
HL Series Desiccant Dryer Models 90-5000
ingersollrandproducts.com
7.0 PRINCIPLES OF OPERATION
• RESET
BUTTONS
• ON
Initiates PLC program. Begins system monitoring
and valve switching functions.
• OFF
Stops PLC program. Stops valve switching
functions. Initiates shutdown sequence. Opens
Inlet Flow Valves. Closes Purge Valves.
• SELECT DISPLAY
Allows the user to scroll through the available
displays. The last display selected will remain
displayed as the default display.
• +/Allows user to modify set point values. Set point
values cycle through a fixed range. Also allows
entering negative numbers in Factory Modes.
•
Õ or “blank” button
Allows user to step backwards to the previous
level of the menu.
Pressing once clears the local alarm indication
and de-energizes the remote alarm contact
for many alarm conditions. Should the alarm
condition persist, the alarm will return after the
alarm inhibit time has expired.
• SET
Permits the adjustment of parameters in
FACTORY MODES.
• ENTER
Used to accept changed parameters and set point
values.
• TEST
Not used in Desiccant Dryer applications
•i
Restricted Level access for factory use only.
The status panel provides clear indication of dryer status via
bright LED indicators.
The following illustration summarizes the panel’s features:
Dryer OFF / Alarm
(Red)
Dryer ON (Green)
Left Tower Regeneration
(Yellow)
Right Tower Regeneration
(Yellow)
Right Tower Drying
(Yellow)
Left Tower Drying
(Yellow)
FIGURE 2 - STATUS PANEL
HL Series Desiccant Dryer Models 90-5000
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7
7.0 PRINCIPLES OF OPERATION
7.8.2 MICROPROCESSOR CONTROL DISPLAY
PARAMETERS
The Microprocessor Controller is capable of
displaying a number of system parameters. The
following summarizes the parameters that can be
accessed by depressing the SELECT DISPLAY button
from the Microprocessor Controller. (Note that some
displays are optional and may not appear on all
models):
• Tower Status {LT DRY / RT REGEN or LT REGEN /
RT DRY}: Provides visual confirmation of tower
drying and regenerating status.
• Step Timer {ie STEP 4 TIME 120}: Information
screen displaying the current step in the program
and the time remaining for the displayed step.
• Dew Point Temperature (OPTIONAL) - {DEW
POINT TEMP: XX}: When equipped with the
Energy Management System (EMS) feature,
provides accurate display of dryer
outlet pressure dew point.
• Purge Status (OPTIONAL) - {PURGE / NO PURGE}:
Indicates whether unit is currently consuming
purging air. Requires EMS.
• Alarms {ALARM LIST - PRESS ENTER}: Depressing
<ENT> at this prompt permits viewing of current
alarm status and alarm history.
• Operating & Purge Times - {OPERATING TIMES PRESS ENTER}: Depressing <ENT> at this prompt
provides access to the operating and purge
hours of operation.
• Operating Mode {OPERATING MODE: HEATLESS}:
open, thus removing the signal to the controller.
During the cycle, the Microprocessor Controller
interrogates the pressure switches to determine
their current position. The Microprocessor Controller
compares their position to a look-up table within
the program. If the position of either switch differs
from the switch’s proper position, the dryer will
initiate the Fail to Shift Alarm.
High Dew Point Alarm (OPTIONAL) - (HIGH DEW
POINT) When the heatless dryer is equipped with
the optional EMS feature, a sensor is provided
that senses the outlet pressure dew point of the
air and displays the value on the Microprocessor
Controller. For dryers equipped with the optional
EMS feature, the sensor is used to detect a high dew
point condition and displays the alarm as “High Dew
Point”.
Alarm List
The Microprocessor Controller stores the 20 most
recent alarm conditions. These alarms are stored
with the type of alarm as well as the date and time
the alarm occurred. This list can greatly facilitate
troubleshooting the dryer and provide an indication
of dryer operation during unattended service. The
following describe the method to access and review
the alarms stored in the Microprocessor Controller:
Depressing the SELECT DISPLAY button will reveal the
previous alarm condition(s), as well as the remaining
available alarm placeholders for alarms. To EXIT the ALARM
LIST, perform the following:
SELECT
DISPLAY
ALARM LIST
PRESS ENTER
Indicates mode of operation for dryer.
7.8.3
ALARMS AND THEIR FUNCTIONS
There are several alarms detected by the
Microprocessor Control to alert the user of an
out of tolerance condition. Once each alarm is
detected, a description of the alarm will appear in
the screen and the remote alarm contact will close.
Note that during the alarm condition, the SELECT
DISPLAY button may be depressed to scroll through
the available parameters. After approximately 30
seconds, the alarm screen will reappear, provided
the alarm condition persists.
Fail to Shift Alarm (OPTIONAL) - (FAIL TO SHIFT)
Pressure switches are provided to detect the
pressure within each tower. At “0” psig the switches
are normally closed which sends a signal to the
controller. When the towers pressurize, the switches
8
Depress the SELECT DISPLAY button until the
ALARM LIST display appears.
ENTER
BEGIN ALARMS
Depressing the ENTER button enters the ALARM
LIST menu.
SELECT
DISPLAY
ALARM OFF
Depressing the SELECT DISPLAY button advances
the menu to the current alarm status.
HL Series Desiccant Dryer Models 90-5000
ingersollrandproducts.com
7.0 PRINCIPLES OF OPERATION
the top of the ALARM LIST.
SELECT
DISPLAY
HIGH DEW POINT
TM 1635 DATE 1104
Depressing the SELECT DISPLAY list displays
the most recent of the alarms stored by the
Microprocessor Control. Refer to the diagram at the
end of this section for an explanation of the ALARM
LIST Display.
ALARM LIST
PRESS ENTER
Depressing the Õ button again returns the
controller to the CUSTOMER MODE.
BEGIN ALARMS
Depressing the Õ button returns the controller to
Alarm Condition
HIGH DEW POINT
TM 1635 DATE 1104
Time of Alarm
(Military Time)
Date of Alarm
(Date-Month)
Example shows April 11
FIGURE 3 - ALARM SCREEN DETAILS
HL Series Desiccant Dryer Models 90-5000
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9
7.0 PRINCIPLES OF OPERATION
7.8.4
RESTART MODES AND OPERATING DISPLAYS
ENTER
7.8.4.1 Restart Mode
The Microprocessor Controller includes a Shutdown
Sequence that is activated when the dryer OFF
button is depressed. This feature positions the
valves to their failsafe position and resets the
program and is the recommended method
of shutting down the dryer. When the dryer is
subsequently energized, the dryer is ready to run at
the start of the program. Should the Desiccant dryer
power fail unexpectedly, the dryer may be set to
restart in one of two start modes.
Manual Mode (ZERO)
Ingersoll Rand dryers are shipped from the factory
in the Manual Mode. After power is supplied to
the dryer after a loss of power, the “PRESS ON”
display will appear. The valve switching and timing
operations will only start once the ON button is
depressed. In this configuration, to restart the dryer,
the user must manually depress the ON button on
the Microprocessor Control panel.
BEGIN TIMES
Depressing the ENTER button enters the OPERATING TIMES
menu.
SELECT
DISPLAY
OPERATING HOURS
000000065
Depressing the SELECT DISPLAY button displays the
cumulative operating hours of the dryer.
SELECT
DISPLAY
PURGE HOURS
000000009
Depressing the SELECT DISPLAY button displays the
cumulative hours the dryer has used purge air.
Auto Restart Mode (LAST)
In this mode, the dryer will start automatically once
power is re-applied to the dryer. The Microprocessor
Control will pick up where it left off in the program
once power is applied.
ENTER
BEGIN TIMES
Depressing the ENTER button returns the display to the top
of the OPERATING TIMES menu.
7.8.4.2 Operation Hours
In the CUSTOMER MODE, the Microprocessor
Controller provides access to the operating hours
of the dryer. The following describe the method to
access and review the operating and purge hours
for the dryer:
SELECT
DISPLAY
OPERATING TIMES
PRESS ENTER
Depressing the Õ button returns the controller to the
CUSTOMER MODE
OPERATING TIMES
PRESS ENTER
Depress the SELECT DISPLAY button until the OPERATING
TIMES display appears.
10
HL Series Desiccant Dryer Models 90-5000
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8.0 ALARMS AND INDICATORS
8.1
MOISTURE INDICATOR
8.4
The moisture indicator senses a sample of the control air
which is taken from the dryer outlet. The indicator provides
a gross indication of dew point deterioration at the outlet of
the dryer. Under normal operating conditions, the indicator
is blue. In the event of a dryer malfunction or prolonged
dryer shut down, it will turn gray in the presence of moisture.
8.2
FAILURE TO SHIFT ALARM (OPTIONAL)
The Failure to Shift Alarm provides an indication of switching
failure in one of the dryer switching valves. The Fail to Shift
Alarm uses a pressure switch to monitor the pressure in each
tower. At “0” PSIG the switches are normally closed which
sends a signal to the controller. When the towers pressurize,
the switches open, thus removing the signal to the
controller. The controller anticipates the appropriate open
and closed switch position based on its timing sequence. If
either switch is in an incorrect position, the alarm light will
illuminate.
8.3
ENERGY MANAGEMENT SYSTEM (EMS) (OPTIONAL)
Ingersoll Rand’s EMS system is designed to minimize
the loss of purge air during low flow or low water loading
conditions. A digital dew point sensor is used to detect
the actual outlet pressure dew point of the process air. The
sensor communicates the pressure dew point reading to the
Microprocessor Controller. The Microprocessor Controller
interprets whether the outlet pressure dew point is above
or at the EMS set point. As long as the outlet pressure
dew point is dryer than the set point, the Microprocessor
Controller will not allow the Purge Valves to open. The
dryer will however, continue to cycle back and forth
between towers. Once the EMS threshold is reached, the
Microprocessor Controller will initiate the regeneration cycle
and the appropriate Purge Valve will open.
HIGH DEW POINT ALARM (INCLUDED WITH
EMS)
The purpose of the High Dew Point Alarm is to provide the
operator an alarm indication should the equipment fail to
supply air at its designed pressure dew point. The EMS dew
point sensor communicates the pressure dew point reading
to the Microprocessor Controller. Should the pressure dew
point rise above the alarm set point, the Microprocessor
Controller will display the alarm condition on the controller
screen.
8.5
COMPRESSOR INTERLOCK
Compressor Interlock adjusts the operation of the dryer to
use purge air only when the air compressor is LOADING or
ON. For installations with significant downstream air storage,
this feature closes the purge valves if the compressor is not
delivering flow after completion of the current tower purge
cycle. This feature requires a relay (supplied by others) on
the air compressor to indicate whether the air compressor
is LOADING or ON vs. UNLOADING or OFF. Prior to using this
feature, the relay must be wired to the 5V DC terminal strip
in the dryer’s electrical enclosure (refer to the appropriate
wiring diagram). The dryer will provide the 5V DC power.
For proper operation, the air compressor ON or LOAD signal
should correspond with the relay being closed. The OFF or
UNLOAD signal must correspond to the relay being open.
Adjusting the purge cycle to correlate with the operation
of the air compressor minimizes the potential for the air
compressor to cycle and saves the energy associated with
generating unnecessary purge air.
NOTICE
At initial start-up or after desiccant changeout, the
new desiccant has a moisture holding capacity higher
than the dryer’s design regeneration capabilities. The
desiccant stabilizes to an “aged” state after three to six
months of use. Ingersoll Rand recommends keeping
the EMS feature off for one to two weeks from initial
start-up or desiccant replacement. Activating the EMS
after this period will insure proper operation of the
EMS.
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11
9.0 INSTALLATION AND INITIAL START-UP
9.1
APPLICATION AND CHECK ANALYSIS
To achieve the best dryer performance, you should carefully
check that the design and installation requirements outlined
below are satisfied.
NOTICE
The standard dryer is not rated for any gas other than
air.
Operating pressure of Ingersoll Rand dryers can range
from 75 -150 PSIG. Air available for your usage will vary with
operating pressure. The maximum design pressure of the
Ingersoll Rand Heatless Dryer is 150 PSIG. For units required
for higher operating pressures, consult your Ingersoll Rand
representative.
The dryer must never be installed where air and/or ambient
temperature exceeds 120°F or drops below +50°F. Locate
dryer to avoid extremes of heat and cold from ambient or
other conditions. Avoid locating dryer outside or where it is
exposed to the elements.
NOTICE
Ingersoll Rand recommends that the mufflers be
cleaned after initial start-up to remove any desiccant
dust generated during shipment. After running dryer
for initial 30 minute period, de-energize / depressurize
dryer and remove mufflers. Disassemble and clean
the removable insert inside the muffler core. Reinstall
mufflers prior to operating dryer.
9.2
LOCATING AND MOUNTING
Lift the dryer only by the lifting points indicated by the
lifting labels on the dryer.
If the dryer has been shipped with desiccant packaged
separately, install the desiccant after locating and mounting.
Desiccant has been provided separate to minimize handling
difficulty and placing unnecessary stress on the dryer
assembly
Bolt the dryer to the foundation using the bolt holes
provided in the base frame. Anchor bolts should project
a minimum of 3.5 inches above the foundation. Refer to
General Arrangement drawing for details.
9.3
PIPING
Pipe the compressed air lines to the inlet and outlet
connections. Locate the pre-filters as close as possible to the
dryer. Ensure the positioning allows for ease of servicing.
Refer to the General Arrangement drawing.
Note that the wet air inlet is at the dryer’s lower manifold,
while the dry air outlet is at the dryer’s upper manifold. In
situations where air supply is required 24 hours a day (it is
12
undesirable to interrupt the airflow), a three valve by-pass
system is recommended to bypass the dryer. Use the fewest
elbows necessary to keep pressure drop at a minimum.
Once all piping has been connected, all joints including
those on the dryer, should be soap bubble tested at line
pressure to ensure no joints have been damaged in transit
and site placement.
9.4
FILTRATION
It is important that a pre-filter and an post-filter be provided
in your dryer installation. All dryers are supplied with a prefilter and post-filter as standard. They are mounted on the
HL1200 and smaller. They are shipped loose on the HL1500
and larger.
NOTICE
All dryers must have proper filtration. A .3 micron
coalescing filter with automatic drain & particulate
after filter must be used as a minimum. Failure to
provide proper filtration for dryer will void warranty.
Coalescing pre-filters, located before the dryer, protect
desiccant beds from contamination by oil, entrained water,
pipe scale, etc., thereby, extending dryer desiccant life.
Locate pre-filters as close to dryer as possible.
It is recommended that a mechanical separator be installed
immediately preceding the pre-filter to remove the bulk
liquid and entrained water.
Particulate post-filters, located after the dryer, help eliminate
the possibility of desiccant dusting and carryover into the air
system.
9.5
DEW POINT TRANSMITTER INSTALLATION
(OPTIONAL)
On dryers equipped with EMS, the dew point transmitter
is shipped in a separate container within the electrical
enclosure to protect the transmitter during shipment. Prior
to using the EMS feature, the transmitter must be installed
in the sensor block located on the side of or behind the
electrical enclosure and the transmitter cable fastened to
the sensor. Note that the transmitter should only be installed
when the dryer is ready to be commissioned.
To install the Dew Point Transmitter:
• Remove Transmitter from original packaging.
• Verify that Washer is placed below Transmitter hex.
• Thread the Transmitter into the Sensor Block as
shown.
• Attach the Transmitter Cable to the Transmitter. Be
sure to fully engage the Transmitter Cable Securing
Screw into the mating thread in the Transmitter.
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9.0 INSTALLATION AND INITIAL START-UP
TRANSMITTER CABLE
SECURING SCREW
TRANSMITTER CABLE
TRANSMITTER
WASHER
SENSING BLOCK
9.6
ELECTRICAL CONNECTION
Make all electrical connections to the dryer as shown on
the wiring diagram. Care must be taken in connecting the
proper voltages.
9.8
NOTICE
Dryer must be grounded with the full sized ground
wire connected to an earth ground.
NOTICE
Dryer must be fused according to NEC with the
size fuse listed on the dryer serial nameplate, or on
specification sheet in technical manual.
Size field connection knock-out for the conduit fitting
required by the NEC.
9.7
and check desiccant level. The level should be consistent
with the level depicted on the Desiccant Fill Chart at the end
of the manual. The initial charge of desiccant is installed in
the dryers at the factory on models HL 2700 and smaller.
DESICCANT LEVEL VERIFICATION
START-UP
• Slowly pressurize the dryer. When the dryer reaches
full operating pressure, check the system for air
leaks. Soap test all joints and fitting. To maintain
desired dew point, any leaks detected must be fixed,
especially those on the outlet side of the dryer.
• Make sure that the purge adjustment valve is open
and air outlet shut off valve (if equipped) is closed.
• For dryers equipped with EMS, remove the dew
point monitor sensor from the electrical enclosure
and install in the sensing block, located beside the
enclosure and attach the sensor cable to the sensor.
Remove desiccant fill port and the top of the desiccant vessel
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9.0 INSTALLATION AND INITIAL START-UP
• Turn on dryer disconnect switch (supplied by
customer) to apply power to the dryer. The LCD
display on the Microprocessor Controller will
illuminate.
• Start dryer by depressing the ON button on the
Microprocessor Controller.
• For the first 30 seconds that the dryer is energized,
both purge valves will remain closed. After 30
seconds, the left tower purge valve will be opened
and depressurization of the left tower will occur.
9.9
SHUT-DOWN SEQUENCE
NOTICE
Prior to removing power or compressed air from the
dryer, depress the OFF button on the Microprocessor
Control This initiates the Shutdown Sequence, which
closes the purge valves, repressurizes the off-line
tower and opens the flow valves. DO NOT REMOVE
POWER OR COMPRESSED AIR FROM THE DRYER
DURING THE SHUTDOWN SEQUENCE.
• With a voltmeter, check the power connections for the
• Maintain a compressed air source to the dryer and a
correct voltage shown on the dryer serial nameplate.
supply of power to the Microprocessor Controller.
• Close and secure all electrical panel covers.
• The Microprocessor Controller will indicate that the
left tower is drying. The dryer will operate in the
sequence described in Section 7.
SHUTDOWN
SEQEUNCE
OFF
• Following depressurization, adjust purge valve as
described in Section 7.4
Depress the OFF button to initiate the SHUTDOWN
SEQUENCE.
NOTICE
At initial start-up, check the dryer operation for one
or two cycles, especially at the time of the tower shift.
Verify that all systems are operating in their proper
order and sequence. If the dryer is not functioning
properly, contact distributor or Ingersoll Rand
Technical Service.
• If the dryer has been in storage or off for an extended
period of time, the Blue Moisture Indicator may be
gray, the High Dew Point Alarm (if equipped) may
be activated and the dew point display (if equipped)
may indicate a high dew point. Depending upon the
duration of idle time, it may take anywhere from one
to twelve hours for the alarm condition to go out, the
BMI to return to its normal blue state and the dew
point to drop.
• Slowly open the outlet valve to gradually pressurize
the down stream piping.
• Permit the dryer to complete the full SHUTDOWN
SEQUENCE (30 seconds)
PRESS ON
Once the PRESS ON Prompt is displayed, the dryer has
completed the SHUTDOWN SEQUENCE. Power and air may
be safely removed from the dryer.
• De-energize the dryer
• Shut down air compressor or bypass dryer
• Close Isolation Valves (if equipped)
Note: On the subsequent Start-up, the outlet isolation
valve should be in the closed position. Slowly open the
valve to build pressure downstream.
NOTICE
When opening the outlet valve, insure drying tower
gauge maintains line pressure. Allowing pressure to
drop in the dryer will result in an overflow condition.
NOTICE
-100° F dryers require flow through the dryer to lower
the pressure dew point to design levels. Failure to
permit air flow through dryer (deadheading) will result
in elevated outlet dew points. Once air is permitted
to flow through the dryer, the pressure dew point will
gradually reduce to design levels.
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10.0 TECHNICIAN MODE
The Microprocessor Control provides a protected
TECHNICIAN MODE to manipulate several parameters
not accessible by the casual operator. Below is a list of
parameters that can be accessed and manipulated by
the technician in the TECHNICIAN MODE:
Parameter
Display
Set Point
DEW POINT ADJUSTER
SETTING
PDP ADJUSTER
-40, -4, +38
ENERGY MANAGEMENT
SYSTEM (OPTIONAL)
EMS
OFF , ON
ENERGY MANAGEMENT
SYSTEM
SETPOINT (OPTIONAL) *
EMS SET POINT
-76 - +68
RESTART MODE
RESTART
LAST, ZERO
PURGE FLOW ADJUSTER
SETTING
PURGE
ADJUSTER
30% - 100%
COMPRESSOR INTERLOCK
SETTING
COMP
INTERLOCK
OFF , ON
HIGH DEW POINT ALARM
ACTIVATION (OPTIONAL)
HIGH DEW
POINT
OFF , ON
Depressing SELECT DISPLAY scrolls through the available
parameters.
10.2
Display
OPERATION MODE
HEATLESS
* NOTE: Setpoints indicated are adjustable ONLY when dryer
is equipped with the EMS. Setpoints are non-adjustable on
dryers without this option
10.1
DEW POINT ADJUSTER (-40 °F DRYERS ONLY)
Dew point adjuster allows the user to select between -40
°F, -4 °F and +38°F pressure dew points. Selecting a higher
(wetter) pressure dew point lengthens the drying cycle,
making the regeneration process commence less frequently
than at lower (dryer) dew points. This results in energy
savings by depressurizing the system less times per hour.
The chart below describes the available outlet pressure dew
points that may be selected along with their respective cycle
times.
ISO
8573.1
Class
In TECHNICIAN MODE, the following parameters can be
viewed but not changed:
Parameter
SET OPMODE
HEATLESS
SELECT
DISPLAY
Pressure
Dew Point
Cycle Regenerations
Length
per hour
2
-40 °F
-40 °C
10 min
12
3
-4 °F
-20 °C
16 min
7.5
4
+38 °F
+3 °C
24 min
5
The following illustrates the method of accessing and
adjusting the dew point adjuster feature
SELECT
DISPLAY
ENTERING TECHNICIAN MODE
PDP ADJUSTER
DEW POINT: -40
WARNING
TECHNICIAN MODE should only be entered by
qualified service personnel. Altering the set points in
TECHNICIAN MODE will have a significant effect on
the operation of the dryer. Incorrect set points may
damage dryer and cause potential serious injury.
Depress the SELECT DISPLAY button until the DEW POINT
ADJUSTER screen is displayed.
+
-
To enter the TECHNICIAN MODE, perform the following
keystrokes:
2
3
BEGIN
TECHNICIAN MODE
Pressing the “2” and “3” buttons simultaneously enters
the TECHNICIAN MODE.
PDP ADJUSTER
DEW POINT: -4
Depress the +/- button until the desired dew point is
displayed. Pressing SELECT DISPLAY saves the current
selection.
10.3
ENERGY MANAGEMENT SYSTEM (OPTIONAL)
10.3.1 DESCRIPTION AND ACTIVATION
The optional Energy Management System (EMS)
feature is designed to minimize the loss of purge
air during low flow or low water loading conditions.
A digital dew point sensor detects the actual
outlet air pressure dew point of the process air.
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10.0 TECHNICIAN MODE
The sensor communicates the pressure dew point
reading to the Microprocessor Controller. Should
the pressure dew point be below the EMS set point,
the Microprocessor Controller will keep the purge
valves closed while the dryer continues to cycle
back and forth between towers, thereby saving
purge air.
4
Use the numbers on the keypad to enter the desired
pressure dew point temperature for the EMS setpoint.
The following illustrates the method of accessing
and adjusting the Energy Management System
feature:
SELECT
DISPLAY
EMS: OFF
EMS SET POINT
-4__
1
EMS SET POINT
-41_
Use the numbers on the keypad to enter the desired
pressure dew point temperature for the EMS setpoint.
ENTER
Depress the SELECT DISPLAY button until the ENERGY
MANAGEMENT SYSTEM screen is displayed.
EMS SET POINT
-41
Depressing ENTER saves the selected set point.
+
-
EMS: ON
Depress the +/- button until the desired set point is
displayed. Pressing SELECT DISPLAY saves the current
selection.
10.3.2 SETPOINT ADJUSTMENT
On dryers equipped with the optional EMS, the
Energy Management System setpoint can be
adjusted to match the dryers requirements to the
desired pressure dew point.
The following illustrates the method of adjusting
the setpoint for the Energy Management System
feature:
SELECT
DISPLAY
EMS SET POINT
-43
NOTICE
The Energy Management System set point should not
be lower (wetter) than the dew point adjuster setting.
Failure to do so will prevent the Energy Management
System feature from operating. In addition, when
operating in EMS, the purge flow adjuster should be
set to 100%.
10.4
HL Dryers can be configured to restart in one of two
operating modes. As described in Section 5, the dryer may
be configured for Manual operation (factory default) or Auto
Restart, which permits the dryer to restart automatically
once power is re-applied to the dryer. The following
illustrates the method of accessing and adjusting the
different start modes for the dryer:
SELECT
DISPLAY
Depress the SELECT DISPLAY button until the EMS SET POINT
screen is displayed.
SET
EMS SET POINT
___
EMS SET POINT
-___
To enter a negative number, depress the +/- button.
Otherwise, proceed to the next step.
RESTART
ZERO
Depress the SELECT DISPLAY button until the START MODE
screen is displayed.
+
-
Pressing the SET button permits the value of the EMS
SETPOINT to be changed
+
-
RESTART MODE
RESTART
LAST
To change the start mode from its current selection to the
alternate setting, depress the +/- button until the desired
set point is displayed. Pressing SELECT DISPLAY saves the
current selection.
10.5
PURGE FLOW ADJUSTER
Purge flow adjuster allows the user to reduce the duration of
the purge cycle to more closely match the inlet conditions
16
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10.0 TECHNICIAN MODE
to the dryer. This feature is well suited for applications
where the dryer is consistently underflowed, allowing only
the required amount of purge air to be used. The purge
flow adjuster feature allows the user to select the relative
duration of the purge cycle, from 30% to 100%, in 10%
increments.
The following illustrates the method of accessing and
adjusting the purge flow adjuster feature
SELECT
DISPLAY
PURGE ADJUST
% PRG SELECT 100
Depress the SELECT DISPLAY button until the PURGE FLOW
ADJUSTER screen is displayed.
+
-
PURGE ADJUST
% PRG SELECT 70
Depress the +/- button until the desired percent purge
is displayed. Pressing SELECT DISPLAY saves the current
selection.
NOTICE
On dryers equipped with the optional Energy
Management System feature, the purge flow
adjuster MUST be set to 100% in order for the Energy
Management System to operate properly.
10.6
COMPRESSOR INTERLOCK
Compressor Interlock adjusts the operation of dryer to
purge only when the air compressor is LOADING or ON.
This feature requires the customer to provide a relay on the
air compressor to indicate whether the air compressor is
LOADING or ON vs. UNLOADING or OFF. Prior to using this
feature, the user must wire the relay to the 5V DC terminal
strip in the dryer’s electrical enclosure. The dryer will provide
the 5V DC power. The air compressor ON or LOAD signal
should correspond with the relay being open. The OFF or
UNLOAD signal must correspond to the relay being closed.
With the Compressor Interlock properly set-up and
activated, the dryer’s purge valves will close when the air
compressor is not making air, as indicated by the OFF or
UNLOAD condition. With the purge cycle corresponding to
the demands of the air dryer, cycling of the air compressor
is minimized and energy savings is realized by only purging
when the air system requires.
The following illustrates the method of accessing and
adjusting the Compressor Interlock feature:
SELECT
DISPLAY
COMP INTERLOCK
OFF
INTERLOCK screen is displayed.
+
-
COMP INTERLOCK
ON
Depress the +/- button until the desired set point is
displayed. Pressing SELECT DISPLAY saves the current
selection.
10.7
HIGH DEW POINT ALARM (INCLUDED WITH
EMS OPTION)
10.7.1 DESCRIPTION AND ACTIVATION
The purpose of the High Dew Point Alarm is to
provide the operator an alarm indication should
the equipment fail to supply air at its designed
pressure dew point. The EMS dew point sensor
communicates the pressure dew point reading to
the Microprocessor Controller. Should the pressure
dew point rise above the alarm set point, the
Microprocessor Controller will display the alarm
condition on the controller screen.
The following illustrates the method of activating
the High Dew Point Alarm feature:
SELECT
DISPLAY
HIGH DEW PT
OFF
Depress the SELECT DISPLAY button until the HIGH DEW
POINT screen is displayed.
+
-
HIGH DEW PT
ON
Depress the +/- button until the desired set point is
displayed. Pressing SELECT DISPLAY saves the current
selection.
10.7.2 SETPOINT ADJUSTMENT
On dryers equipped with the optional EMS, the High
Dew Point Alarm setpoint can be adjusted.
The following illustrates the method of adjusting
the setpoint for the High Dew Point Alarm feature:
SELECT
DISPLAY
HI PDP SETPOINT
-10
Depress the SELECT DISPLAY button until the HIGH DEW
POINT ALARM SET POINT screen is displayed.
Depress the SELECT DISPLAY button until the COMPRESSOR
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17
10.0 TECHNICIAN MODE
SET
HI PDP SETPOINT
___
Pressing the SET button permits the value of the HIGH DEW
POINT ALARM SET POINT to be changed.
+
-
HI PDP SETPOINT
-___
To enter a negative number, depress the +/- button.
Otherwise, proceed to the next step.
2
HI PDP SETPOINT
-2__
Use the numbers on the keypad to enter the desired
pressure dew point temperature for the HIGH DEW POINT
ALARM setpoint.
1
HI PDP SETPOINT
-21_
ENTER
Depressing ENTER saves the selected set point.
NOTICE
The High Dew Point Alarm set point should not be
greater than the Energy Management System set
point or the dew point adjuster setting. Failure to do
so will result in an alarm indication. Ingersoll Rand
recommends setting the High Dew Point Alarm at least
10°F wetter than the Energy Management System or
dew point adjuster setpoints.
NOTICE
To exit the TECHNICIAN MODE, press the “+ / -” key to
the initial “SETOPMODE” screen and depress the Õ
button to return to the CUSTOMER MODE.
Ingersoll Rand desiccant dryers are capable of remote
communications via MODBUS. Refer to the document
entitled, “Microprocessor Control Modbus Communications
Guide” for details on communicating with the Controller via
MODBUS.
Use the numbers on the keypad to enter the desired
pressure dew point temperature for the HIGH DEW POINT
ALARM setpoint.
18
HI PDP SETPOINNT
-21
HL Series Desiccant Dryer Models 90-5000
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11.0 MAINTENANCE AND SYSTEM CHECK
11.1
SCHEDULED MAINTENANCE
EVERY THREE - TO - FIVE YEARS:
DAILY MAINTENANCE FUNCTIONS:
• Check and record inlet pressure, temperature and
• Replace desiccant.
• Rebuild purge and switching diaphragm valves
(Preventative)
flow. Verify that it is within specifications.
• Check tower pressure gauge readings within
operating tolerance.
• Check operation for proper dryer cycling,
depressurization and repressurization.
• Check that the pre-filter drain is operating properly
and that there is no condensate discharged from
purge mufflers. Replace cartridges sooner if necessary
as required by differential pressure indicator.
• Verify that pressure in purging tower is 10 PSIG or
less. If higher, muffler replacement is recommended.
(Section 11.4)
• Verify that pre-filter and post-filter differential
pressure is within operating limits. Change as
required. (Section 11.2). Replace cartridges sooner
if necessary as required by differential pressure
indicator.
• Check the Blue Moisture Indicator. Make sure air is
bleeding through the indicator. The indicator will be
blue when air is dry.
SEMI-ANNUAL MAINTENANCE FUNCTIONS:
• Check outlet dew point.
• Check pilot air filter element and clean or replace as
• Replace Check Valves (Preventative)
11.2
PRE-FILTERS AND POST-FILTERS
• Pre-filters - The cartridges of the pre-filter must
be changed as often as required to prevent
contamination of the regenerative dryer’s desiccant
bed.
The pre-filter and automatic drain must be checked daily.
To prolong filter cartridge life, it is recommended that a
mechanical air / moisture separator be placed immediately
before the pre-filter.
NOTICE
Should the drying system be overloaded and/or
malfunctioning, causing high pressure drop, postfilters will prematurely plug. This problem can
be avoided by frequent inspection and proactive
replacement of cartridges.
• Post-filters - The purpose of the post-filter is to
remove residual desiccant dust. Depending upon
equipment application and usage, frequency of
filter element change will vary. It is recommended to
change filter element every six months as a minimum.
WARNING
required.
• Replace pre-filter and post-filter elements and / or
cartridges. Replace cartridges sooner if necessary as
required by differential pressure indicator.
ANNUAL MAINTENANCE FUNCTIONS:
• Check desiccant and replace if necessary.
• Inspect and clean pilot air control no-loss drain valves,
To avoid injury, depressurize dryer before performing
any service.
11.2.1 THREADED FILTERS:
Refer to “F35 - F2378 (G, H, A, D) Operators Manual”
(CCN 85566024) for element change-out procedures for
threaded filters.
check valves and diaphragm valves. Rebuild and / or
replace as required.
• Test lights and switches, replace as necessary.
• Test electrical components, replace as necessary.
EVERY TWO YEARS:
• Replace diaphragm and seal kits on purge and
switching diaphragm valves.
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11.0 MAINTENANCE AND SYSTEM CHECK
11.2.2 FLANGED FILTERS:
11.3
PILOT AIR CONTROL NO-LOSS DRAIN VALVES
The length of time the pilot air valves can reliably operate
without replacing is dependent upon the type of dryer
and the dryer’s operation. On Ingersoll Rand -40°F dew
point dryers, replacing the valves is recommended every 60
months. Given the difference in cycle times for -100°F units,
these dryers should have their pilot valves replaced every 30
months.
11.4
STEP 1 - Using
a 2" socket with
an extension,
carefully loosen
element.
STEP 2 Remove old
element from
filter housing.
STEP 3 - Install
new element by
carefully
inserting
element in top
plate.
STEP 4 - Hand
tighten element
in place until
element o-ring
contacts top
plate.
STEP 5 - Using
a 2" socket with
an extension,
tighten element
one half turn.
DO NOT OVERTIGHTEN.
STEP 6 Repeat
procedure as
required to
replace all
elements.
• Normally Open (N.O.) Valves: For N.O. inlet or
repressurization valves, control air is supplied to the
top port. The back side port exhausts out the bottom
side of the diaphragm. If air leaks continuously when
control air is supplied to the valve, the internal seals
are leaking and must be replaced.
• Normally Closed (N.C.) Valves: For N.C. purge valves,
the top port is plugged. Control air is supplied
to the back port. If air vents out of the back port
continuously when the solenoid is de-energized, it
will exhaust through the top of the solenoid. If this
condition is observed, the internal seals are leaking
and must be replaced.
MUFFLER CHANGEOUT PROCEDURE
WARNING
To avoid injury, depressurize dryer before performing
any service.
• Depressurize the dryer turn control power off.
• Replace muffler.
• Follow Start-up procedure described in Section 9.7.
• Turn control power back on.
11.5
PURGE AND SWITCHING DIAPHRAGM
VALVES (HL90 - HL 2700)
These valves have two control ports; one on top and the
other on the back side.
20
11.6
PILOT OPERATED ACTUATOR (HL3300 HL5000)
Should the actuator fail to rotate, disconnect the pilot lines
to check if the actuator is receiving pilot pressure.
If the actuator is receiving pressure:
• Verify that control pressure is 75 psig min.
• Ensure the inlet valve is not plugged.
11.7
OUTLET CHECK VALVES
Outlet check valves sealing can be verified by depressurizing
the dryer and slowly applying pressure to the outlet. The
valves should seal and prevent air from pressurizing the
towers. If a tower begins to pressurize, the check valve on
that side requires replacement.
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11.0 MAINTENANCE AND SYSTEM CHECK
11.8
DESICCANT CHANGEOUT PROCEDURE
When it becomes necessary to replace the desiccant in the
towers, observe the following procedure:
WARNING
To avoid injury, depressurize dryer before performing
any service.
CAUTION
Be sure to wear respiratory protection during the
draining and filling process to minimize inhalation of
desiccant, as desiccant will produce dust during this
procedure.
NOTICE
Each dryer is shipped with a desiccant sample kit to
allow the desiccant to be sent for analysis. This kit can
be used to have the condition of the desiccant verified
by laboratory analysis. Please follow the instructions
found in the kit.
• The standard units are furnished with fill and drain
• To assist in getting the desiccant to flow from the
tower, insert a small rod in to the drain port as
necessary. This may be required as the desiccant is
packed into the towers which may interfere with the
desiccant flow from the towers.
• Retainer screens, located at the inlet and outlet
piping connections of the tower, are removable on all
models. It is suggested that these screens be removed
and cleaned at the time of desiccant changeout.
These screens can be accessed by disconnecting the
upper and lower manifolds from the dryer towers.
• After cleaning the retainer screens, replace screens
and reattach the outlet port plug.
• With the fill port plug removed, fill the dryer tower
with the appropriate grade and size desiccant.
The level of the desiccant should be below the top
retainer screen as shown on the Desiccant Fill Chart
below.
• Once the towers have been filled, replace the fill port
plug on each tower.
• Any connections disturbed in the desiccant
changeout process should be leak tested prior to recommissioning the dryer.
ports on each desiccant tower. Remove the caps on
both ports.
HL Series Desiccant Dryer Models 90-5000
ingersollrandproducts.com
21
11.0 MAINTENANCE AND SYSTEM CHECK
Model No.
HL90
HL120
HL160
HL200
HL250
HL300
HL400
HL500
HL600
HL800
A
20”
7”
18”
7”
16”
7”
8”
20”
10”
27”
B
30”
20.38”
29.75”
21.50”
28”
21.25”
22.25”
34.75”
27.50”
41”
Model No.
HL1000
HL1200
HL1500
HL1800
HL2100
HL2700
HL3300
HL4000
HL5000
A
14.5”
4”
6”
31.50”
22”
6”
16.25”
7.75”
9”
Tolerance = +/- .50”
B
31.5”
23.75”
23.25”
45.75”
38.5”
26”
5.25”
29”
28”
DESICCANT FILL CHART
MODEL LB. AA -40°C LB. AA -100°C
No.
DRYERS
DRYERS
HL90
100
75
HL120
134
101
HL160
192
144
HL200
236
177
HL250
290
218
HL300
344
258
HL400
470
353
HL500
638
479
HL600
748
561
HL800
900
675
HL1000
1100
825
HL1200
1270
953
HL1500
1600
1200
HL1800
2000
1500
HL2100
2340
1755
HL2700
2928
2196
HL3300
3800
2850
HL4000
4226
3200
HL5000
5138
3850
AA = ACTIVATED ALUMINA
MS = MOLECULAR SIEVE
22
LB. MS -100°C
DRYERS
25
34
48
59
73
86
118
160
187
225
275
318
400
500
585
732
950
1026
1288
DESCRIPTION
PART #
ACTIVATED ALUMINA QTY. (1) 50 LB. BAG
38004834
ACTIVATED ALUMINA QTY. (42) 50 LB. BAGS
38004933
ACTIVATED ALUMINA QTY. (1) 2000 LB. SACK
38340659
MOLECULAR SIEVE QTY. (1) 275 LB. DRUM
38449971
NOTE: Qty. is per dryer
HL Series Desiccant Dryer Models 90-5000
ingersollrandproducts.com
12.0 TROUBLESHOOTING
Refer to maintenance descriptions in Section 11as required for trouble shooting procedures.
PROBLEM
PROBABLE CAUSE
CORRECTIVE ACTION
Elevated dew point
Insufficient purge rate
Check purge flow settings.
Check purge piping for obstruction.
Clean purge piping and muffler.
Inlet air pressure below design condition.
Check pressure source and system for leakage.
Flow rate higher than design condition.
Check flow rate and cause for increased demand.
Correct flow rate condition.
Check aftercooler, clean and service as necessary.
Inlet temperature above design condition
(120°F).
Entrained water entering desiccant bed.
Blue Moisture Indicator
(BMI) indicates high
moisture level.
Excessive pressure drop
in dryer
Excessive flow rate.
Check air/moisture separator and pre-filter. Replace dryer
desiccant if necessary.
Install suitable pre-filter. Replace dryer desiccant.
Refer to “Elevated Dew Point” corrective actions above.
Depending on degree of saturation of the desiccant, the BMI may
take a week or more of continuous use to switch back to its blue
(dry) state.
Check flow rate and cause for increased air demand.
Inlet pressure below design condition.
Check pressure source.
Desiccant contaminated by oil.
Elevated dew point
BMI wet
Failure to Shift (Switching No input power
Failure)
Defective solenoid valve
No pilot air
Pilot-operated diaphragm valve seal failure
Check power input.
Check solenoid valve.
Check pilot air line. Check that control air line filter is clean.
Inspect and replace seals as required.
Dryer fails to pressurize.
Faulty purge valve
Check that repressurization circuit is sending control
signal.
Check purge valve and its solenoid valve.
Dryer depressurizes too
rapidly.
Dryer fails to purge.
Purge valve does not close; dryer
repressurizing through inlet valve.
Purge valve does not open. Purge valve stuck
in closed position.
Check purge valve and its solenoid valve.
Excessive back pressure
in regenerating tower
(above 5 psig)
Purge muffler does not pass air.
Check purge valve and its solenoid valve. Repair and
replace if necessary.
Check that repressurization circuit is sending control signal.
Purge muffler is dirty; replace.
Purge muffler passes too much air. Air is
leaking across valve.
Improper calibration.
Check inlet valve and outlet check valves. Verify inlet valve is
closed to purging tower (0 psig tower).
Reset when right tower is on line.
Right tower excessively
high pressure at the purge
gauge.
HL Series Desiccant Dryer Models 90-5000
ingersollrandproducts.com
23
13.0 PURGE CHARTS
Purg e O rific e - 9/64"
H L90 Settin g - 65 p s ig @ 14 SC F M
16
Purge Air Flow SCFM
14
12
10
8
6
4
2
0
0
10
20
30
40
50
60
70
Purge Meter Setting - psig
Purge Orifice - 5/32"
Purge Orifice - 3/16"
HL120 Setting - 53 psig @ 19 SCFM
HL160 Setting - 50 psig @ 26 SCFM
22
35
30
18
Purge Air Flow - SCFM
Purge Air Flow - SCFM
20
16
14
12
10
8
6
4
25
20
15
10
5
2
0
0
0
10
20
30
40
50
60
70
0
10
Purge Meter Setting - psig
35
Purge Air Flow - SCFM
Purge Air Flow - SCFM
40
30
25
20
15
10
5
0
30
40
50
60
0
70
70
10
20
30
40
50
60
70
60
70
Purge Meter Setting - psig
Purge Orifice - 9/32"
Purge Orifice - 5/16"
HL300 Setting - 40 psig @ 48 SCFM
HL400 Setting - 45 psig @ 65 SCFM
90
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
80
Purge Air Flow - SCFM
Purge Air Flow - SCFM
60
60
55
50
45
40
35
30
25
20
15
10
5
0
Purge Meter Setting - psig
70
60
50
40
30
20
10
0
0
10
20
30
40
50
60
70
0
10
20
Purge Meter Setting - psig
24
50
HL250 Setting - 42 psig @ 40 SCFM
45
20
40
Purge Orifice - 1/4"
Purge Orifice - 7/32"
10
30
Purge Meter Setting - psig
HL200 Setting - 42 psig @ 30 SCFM
0
20
HL Series Desiccant Dryer Models 90-5000
ingersollrandproducts.com
30
40
50
Purge Meter Setting - psig
13.0 PURGE CHARTS
Purge Orifice - 3/8"
Purge Orifice - 3/8"
HL600 Setting - 41 psig @ 93 SCFM
130
120
110
100
90
80
70
60
50
40
30
20
10
0
Purge Air Flow - SCFM
Purge Air Flow - SCFM
HL500 Setting - 35 psig @ 81 SCFM
0
10
20
30
40
50
60
130
120
110
100
90
80
70
60
50
40
30
20
10
0
0
70
10
30
40
50
60
70
60
70
60
70
Purge Orifice - 1/2"
HL1000 Setting - 43 psig @ 162 SCFM
Purge Orifice - 7/16"
HL800 Setting - 46 psig @ 130 SCFM
220
180
200
160
180
140
Purge Air Flow - SCFM
Purge Air Flow - SCFM
20
Purge Meter Setting - psig
Purge Meter Setting - psig
120
100
80
60
40
160
140
120
100
80
60
40
20
20
0
0
0
10
20
30
40
50
60
0
70
10
20
30
40
50
Purge Meter Setting - psig
Purge Meter Setting - psig
Purge Orifice - 9/16"
HL1200 Setting - 41 psig @ 195 SCFM
Purge Orifice - 5/8"
HL1500 Setting - 41 psig @ 243 SCFM
300
240
Purge Air Flow - SCFM
Purge Air Flow - SCFM
270
210
180
150
120
90
60
30
0
0
10
20
30
40
50
60
70
360
330
300
270
240
210
180
150
120
90
60
30
0
0
10
Purge Meter Setting - psig
HL Series Desiccant Dryer Models 90-5000
ingersollrandproducts.com
20
30
40
50
Purge Meter Setting - psig
25
13.0 PURGE CHARTS
Purge Orifice - 5/8"
Purge Orifice - 3/4"
HL2100 Setting - 40 psig @ 340 SCFM
360
330
300
270
240
210
180
150
120
90
60
30
0
500
450
Purge Air Flow - SCFM
Purge Air Flow - SCFM
HL1800 Setting - 51 psig @ 292 SCFM
400
350
300
250
200
150
100
50
0
0
10
20
30
40
50
60
0
70
10
20
30
40
50
60
70
60
70
Purge Meter Setting - psig
Purge Meter Setting - psig
Purge Orifice - 3/4"
P urg e O rif ic -e7/8"
HL3300 S e ttin g - 4 7 p sig @ 5 3 5 S C FM
HL2700 Setting - 53 psig @ 438 SCFM
500
700
400
Purge Air Flow - SCFM
Purge Air Flow - SCFM
450
350
300
250
200
150
100
600
500
400
300
200
100
50
0
0
0
10
20
30
40
50
60
0
70
10
20
P u rg e A ir F lo w - S C F M
900
800
Purge Air Flow - SCFM
40
50
P urg e O rif ic e - 1"
H L5000 S e ttin g - 5 6 p sig @ 8 1 1 S C FM
P urg e O rif ic e - 1"
H L4000 S e ttin g - 4 4 p sig @ 6 4 9 S C FM
700
600
500
400
300
200
100
900
800
700
600
500
400
300
200
100
0
0
10
20
30
40
50
60
70
0
0
10
Purge Meter Setting - psig
26
30
Purge Meter Setting - psig
Purge Meter Setting - psig
HL Series Desiccant Dryer Models 90-5000
ingersollrandproducts.com
20
30
40
50
Purge Meter Setting - psig
60
70
GENERAL ARRANGEMENT
HL90-HL120
580000-G
14.0 GENERAL ARRANGEMENT
HL Series Desiccant Dryer Models 90-5000
ingersollrandproducts.com
27
GENERAL ARRANGEMENT
HL160-HL200
580001-E
14.0 GENERAL ARRANGEMENT
28
HL Series Desiccant Dryer Models 90-5000
ingersollrandproducts.com
GENERAL ARRANGEMENT
HL250-HL300
580002-F
14.0 GENERAL ARRANGEMENT
HL Series Desiccant Dryer Models 90-5000
ingersollrandproducts.com
29
GENERAL ARRANGEMENT
HL400
580003-E
14.0 GENERAL ARRANGEMENT
30
HL Series Desiccant Dryer Models 90-5000
ingersollrandproducts.com
GENERAL ARRANGEMENT
HL500-HL600
580004-E
14.0 GENERAL ARRANGEMENT
HL Series Desiccant Dryer Models 90-5000
ingersollrandproducts.com
31
GENERAL ARRANGEMENT
HL800-HL1200
580005-G
14.0 GENERAL ARRANGEMENT
32
HL Series Desiccant Dryer Models 90-5000
ingersollrandproducts.com
GENERAL ARRANGEMENT
HL1500
580006-F
14.0 GENERAL ARRANGEMENT
HL Series Desiccant Dryer Models 90-5000
ingersollrandproducts.com
33
GENERAL ARRANGEMENT
HL1800-HL2100
580029-E
14.0 GENERAL ARRANGEMENT
34
HL Series Desiccant Dryer Models 90-5000
ingersollrandproducts.com
GENERAL ARRANGEMENT
HL2700
580007-F
14.0 GENERAL ARRANGEMENT
HL Series Desiccant Dryer Models 90-5000
ingersollrandproducts.com
35
GENERAL ARRANGEMENT
HL3300-HL4000
580092-F
14.0 GENERAL ARRANGEMENT
36
HL Series Desiccant Dryer Models 90-5000
ingersollrandproducts.com
GENERAL ARRANGEMENT
HL5000
580306-C
14.0 GENERAL ARRANGEMENT
HL Series Desiccant Dryer Models 90-5000
ingersollrandproducts.com
37
WIRING DIAGRAM
HL90-HL5000
TM-580078-C
15.0 WIRING DIAGRAM
38
HL Series Desiccant Dryer Models 90-5000
ingersollrandproducts.com
FLOW DIAGRAM
HL90-HL2700
580022-E
16.0 FLOW DIAGRAM
HL Series Desiccant Dryer Models 90-5000
ingersollrandproducts.com
39
FLOW DIAGRAM
HL90-HL5000
580213-D
16.0 FLOW DIAGRAM
40
HL Series Desiccant Dryer Models 90-5000
ingersollrandproducts.com
17.0 REPLACEMENT PARTS
HL901H00
AA
DESCRIPTION
BLUE MOISTURE INDICATOR
DESICCANT, 4-8mm GRADE D
DISPLAY BOARD, PANEL
DRYER CONTROLLER, TYPE 4 WITH
DESICCANT PROGRAM (Dryer
model and serial number must
be provided with order to ensure
proper configuration.)
ELEMENT, PILOT AIR FILTER
ELEMENT, PRE-FILTER 105 SCFM
ELEMENT, PRE-FILTER 125 SCFM
ELEMENT, PRE-FILTER 233 SCFM
ELEMENT, PRE-FILTER 250 SCFM
ELEMENT, POST-FILTER 105 SCFM
ELEMENT, POST-FILTER 125 SCFM
ELEMENT, POST-FILTER 233 SCFM
ELEMENT, POST-FILTER 250 SCFM
GAUGE, PURGE/TOWER PRESSURE
2 1/2”
MUFFLER, PURGE, 1/2”
MUFFLER, PURGE, 1”
OVERLAY, CONTROLLER
POWER SUPPLY, 5V/24VDC
RESISTOR, 5V LOAD, 200 OHM
RETAINER, DESICCANT SCREEN
ASSEMBLY
VALVE, DIAPHRAGM, 1” P.O.N.O.
VALVE, DIAPHRAGM, 1 1/2” P.O.N.O.
VALVE, DIAPHRAGM, 2” P.O.N.O.
VALVE, DIAPHRAGM, 3/4” P.O.N.C
VALVE, DIAPHRAGM, 1” P.O.N.C.
VALVE, BALL, CONTROL AIR, 1/4”
VALVE, BALL, PURGE, 1/2”
VALVE, BALL PURGE, 3/4”
VALVE, CHECK, PURGE, 1/2”
VALVE, CHECK, PURGE, 3/4”
VALVE, CHECK, FLOW, 1”
VALVE, CHECK, FLOW, 1 1/2”
VALVE, SAFETY/RELIEF 1/4”
VALVE, SOLENOID, CONTROL AIR,
24VDC MINI
QTY/
HL1201H00
AA
HL1601H00
AA
HL2001H00
AA
HL2501H00
AA
705001-SP 705001-SP
NOTE 1
NOTE 1
633653
633653
705001-SP
NOTE 1
633653
705001-SP
NOTE 1
633653
705001-SP
1
NOTE 1
NOTE 1
633653
1
800030
800030
800030
800030
680572
SPARES
2
3
800030
Refer to page 45 for Pilot Air Filter Element Section
85565679
85565711
85565752 85565752
85565794
85565661
85565703
85565745 85565745
85565786
680572
UNIT
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
1
1
1
680572
680572
680572
3
680619
680619
634086
634086
633665-SP 633665-SP
683968
683968
680454
634086
633665-SP
683968
680454
634086
633665-SP
683968
680454
634086
633665-SP
683968
2
2
1
1
1
705604-SP 705604-SP
705604-SP
705180-SP
705180-SP
4
630721
630569
681621
680029
AD0510
632790
630730
630721
630569
681621
680029
AD0510
632790
630730
630725
630725
681621
680029
AD0510
632790
630730
630725
630725
681621
680029
AD0510
632791
630730
630725
630725
681621
680429
AD0515
632791
630730
2
2
2
2
2
1
1
1
2
2
2
2
2
633658
633658
633658
633658
633658
1
NOTE 1: Refer to the Desiccant Fill Chart in the Maintenance section.
Spare. Quantities under this heading reflect the number of each item which we recommend be kept on hand for
maintenance or repair.
The appropriate quantity for your application will depend on how critical interruptions in service are to your operation.
Class
Quantity
Suggested for
1
2
3
Minimum
Average
Maximum
Domestic service where interruptions in service are acceptable.
Domestic service where some interruptions in service are acceptable.
Export service or for domestic service where interruptions in service are unacceptable.
HL Series Desiccant Dryer Models 90-5000
ingersollrandproducts.com
41
17.0 REPLACEMENT PARTS
DESCRIPTION
HL3001H00 HL4001H00
AA
AA
HL5001H00
AA
HL6001H00
AA
HL8001H00
AA
QTY/
UNIT
SPARES
1 2 3
BLUE MOISTURE INDICATOR
705001-SP 705001-SP 705001-SP 705001-SP 705001-SP
1
DESICCANT, 4-8mm GRADE D
NOTE 1
NOTE 1
NOTE 1
NOTE 1
NOTE 1 NOTE 1
DISPLAY BOARD, PANEL
633653
633653
633653
633653
633653
1
DRYER CONTROLLER, TYPE 4 WITH
DESICCANT PROGRAM (Dryer
800030
800030
800030
800030
800030
1
model and serial number must be
provided with order to ensure proper
configuration.)
ELEMENT, PILOT AIR FILTER
Refer to page 45 for Pilot Air Filter Element Section
1
1 1
ELEMENT, PRE-FILTER 339 SCFM
85565836
1
1 1
ELEMENT, PRE-FILTER 466 SCFM
85565877
1
1 1
ELEMENT, PRE-FILTER 580 SCFM
85565919
1
1 1
ELEMENT, PRE-FILTER 680 SCFM
85565968
1
1 1
ELEMENT, PRE-FILTER 900 SCFM
85565992
1
1 1
ELEMENT, POST-FILTER 339 SCFM
85565828
1
1 1
ELEMENT, POST-FILTER 466 SCFM
85565869
1
1 1
ELEMENT, POST-FILTER 580 SCFM
85565901
1
1 1
ELEMENT, POST-FILTER 680 SCFM
85565950
1
1 1
ELEMENT, POST-FILTER 900 SCFM
85565984
1
1 1
GAUGE, PURGE/TOWER PRESSURE 2 1/2” 680572
680572
680572
680572
3
GAUGE, PURGE/TOWER PRESSURE 3 1/2”
631324
3
MUFFLER, PURGE, 1” MPT
680454
680454
680454
680454
2
2 2
MUFFLER, PURGE, 1 1/2”
680711
2
2 2
OVERLAY, CONTROLLER
634086
634086
634086
634086
634086
1
POWER SUPPLY, 5V/24VDC
633665-SP 633665-SP 633665-SP 633665-SP 633665-SP
1
1 1
RESISTOR, 5V LOAD, 200 OHM
683968
683968
683968
683968
683968
1
RETAINER, DESICCANT SCREEN
705180-SP
705180-SP 705180-SP
4
ASSEMBLY
RETAINER, DESICCANT SCREEN
704972-SP
4
ASSEMBLY 2”
RETAINER, DESICCANT SCREEN
725195-SP 725195-SP
4
ASSEMBLY 3 X 2
RETAINER, DESICCANT SCREEN
725139-SP
4
ASSEMBLY 3”
VALVE, DIAPHRAGM, 1” P.O.N.C.
630575
630575
630575
630575
2
VALVE, DIAPHRAGM, 1 1/2” P.O.N.C.
630572
2
VALVE, DIAPHRAGM, 2” P.O.N.O.
633667
633667
633667
633667
2
VALVE, DIAPHRAGM, 3” P.O.N.O.
631478
2
VALVE, BALL, CONTROL AIR, 1/4”
681621
681621
681621
681621
681621
1
VALVE, BALL, PURGE ADJUST, 3/4”
680429
680429
680429
680429
1
VALVE, BALL, PURGE ADJUST, 1 1/2”
680712
1
VALVE, CHECK, PURGE, 3/4”
AD0515
AD0515
AD0515
AD0515
2
VALVE, CHECK, PURGE, 1 1/2”
683983
2
VALVE, CHECK, FLOW, 1 1/2”
632791
VALVE, CHECK, FLOW, 2”
632792
632792
632792
2
VALVE, CHECK, FLOW, 3”
632794
2
VALVE, SAFETY/RELIEF 1/4”
630730
630730
630730
630730
2
VALVE, SAFETY/RELIEF 1/2”
680896
2
VALVE, SOLENOID 24VDC MINI
633658
633658
633658
633658
633658
1
NOTE 1: Refer to the Desiccant Fill Chart in the Maintenance section.
Spare. Quantities under this heading reflect the number of each item which we recommend be kept on hand for
maintenance or repair.
The appropriate quantity for your application will depend on how critical interruptions in service are to your operation.
Class
Quantity
Suggested for
1
2
3
Minimum
Average
Maximum
Domestic service where interruptions in service are acceptable.
Domestic service where some interruptions in service are acceptable.
Export service or for domestic service where interruptions in service are unacceptable.
42
HL Series Desiccant Dryer Models 90-5000
ingersollrandproducts.com
1
1
1
1
1
1
1
1
1
1
1
2
2
1
17.0 REPLACEMENT PARTS
DESCRIPTION
HL10001H00 HL12001H00
AA
AA
HL15001H00
AA
HL18001H00
AA
HL21001H00
AA
BLUE MOISTURE INDICATOR
705001-SP 705001-SP 705001-SP 705001-SP 705001-SP
DESICCANT, 4-8mm GRADE D
NOTE 1
NOTE 1
NOTE 1
NOTE 1
NOTE 1
DISPLAY BOARD, PANEL
633653
633653
633653
633653
633653
DRYER CONTROLLER, TYPE 4 WITH
DESICCANT PROGRAM (Dryer
model and serial number must
800030
800030
800030
800030
800030
be provided with order to ensure
proper configuration.)
ELEMENT, PILOT AIR FILTER
Refer to page 45 for Pilot Air Filter Element Section
ELEMENT, PRE-FILTER 1070 SCFM
85566230
ELEMENT, PRE-FILTER 1250 SCFM
85566248
ELEMENTS, PRE-FILTER 1800 SCFM
38446357
38446357
ELEMENTS, PRE-FILTER 2400 SCFM
38446357
ELEMENT, POST-FILTER 1070 SCFM 85566214
ELEMENT, POST-FILTER 1250 SCFM
85566222
ELEMENT, POST-FILTER 1800 SCFM
23553357
23553357
ELEMENT, POST-FILTER 2400 SCFM
23553357
GAUGE, PURGE/TOWER PRESSURE
631324
631324
631324
631324
631324
3 1/2”
MUFFLER, PURGE, 1 1/2”
680711
680711
MUFFLER, PURGE, 2”
680455
680455
680455
OVERLAY, CONTROLLER
634086
634086
634086
634086
634086
POWER SUPPLY, 5V/24VDC
633665-SP 633665-SP 633665-SP 633665-SP 633665-SP
RESISTOR, 5V LOAD, 200 OHM
683968
683968
683968
683968
683968
RETAINER, SCREEN ASSEMBLY 3”
725139-SP 725139-SP
RETAINER, SCREEN ASSEMBLY 4”
725140-SP 725269-SP 725269-SP
VALVE, DIAPHRAGM,1 1/2” P.O.N.C.
630572
630572
VALVE, DIAPHRAGM, 2” P.O.N.C.
633701
633701
633701
VALVE, DIAPHRAGM, 3” P.O.N.O.
631478
631478
VALVE, DIAPHRAGM, 4” P.O.N.O.
630406
630406
630406
VALVE, BALL, CONTROL AIR, 1/4”
681621
681621
681621
681621
681621
VALVE, BALL, PURGE ADJUST, 1
680712
680712
680712
680712
680712
1/2”
VALVE, BALL, PURGE ADJUST, 2”
VALVE, CHECK, PURGE, 1 1/2”
683983
683983
683983
683983
683983
VALVE, CHECK, FLOW, 3”
632794
632794
632794
632794
632794
VALVE, SAFETY/RELIEF 1/2”
680896
680896
680896
VALVE, SAFETY/RELIEF 3/4”
AD1415
AD1415
VALVE, SOLENOID 24VDC MINI
633658
633658
633658
633658
633658
QTY/
UNIT
SPARES
1
2
3
1
1
1
3
4
1
1
3
4
1
1
1
3
4
1
1
3
4
1
1
1
3
4
1
1
3
4
1
NOTE 1
1
1
1
1
1
3
4
1
1
3
4
3
2
2
1
1
1
4
4
2
2
2
2
1
2 2 2
2 2 2
1 1 1
1
1
2
2
2
2
1
NOTE 1: Refer to the Desiccant Fill Chart in the Maintenance section.
Spare. Quantities under this heading reflect the number of each item which we recommend be kept on hand for
maintenance or repair.
The appropriate quantity for your application will depend on how critical interruptions in service are to your operation.
Class
Quantity
Suggested for
1
2
3
Minimum
Average
Maximum
Domestic service where interruptions in service are acceptable.
Domestic service where some interruptions in service are acceptable.
Export service or for domestic service where interruptions in service are unacceptable.
HL Series Desiccant Dryer Models 90-5000
ingersollrandproducts.com
43
17.0 REPLACEMENT PARTS
DESCRIPTION
BLUE MOISTURE INDICATOR
DESICCANT, 4-8mm GRADE D
DISPLAY BOARD, PANEL
DRYER CONTROLLER, TYPE 4 WITH
DESICCANT PROGRAM (Dryer model and
serial number must be provided with
order to ensure proper configuration.)
ELEMENT, PILOT AIR FILTER
ELEMENT, PRE-FILTER 3000 SCFM
ELEMENT, PRE-FILTER 3600 SCFM
ELEMENT, PRE-FILTER 4200 SCFM
ELEMENT, PRE-FILTER 6000 SCFM
ELEMENT, POST-FILTER 3000 SCFM
ELEMENT, POST-FILTER 3600 SCFM
ELEMENT, POST-FILTER 4200 SCFM
ELEMENT, POST-FILTER 6000 SCFM
GAUGE, PURGE/TOWER PRESSURE 3 1/2”
MUFFLER, PURGE, 2”
OVERLAY, CONTROLLER
POWER SUPPLY, 5V/24VDC
RESISTOR, 5V LOAD, 200 OHM
RETAINER, SCREEN ASSEMBLY 4”
RETAINER, SCREEN ASSEMBLY 6”
VALVE, DIAPHRAGM, 2” P.O.N.C.
VALVE, DIAPHRAGM, 3/ 4” P.O.N.O.
VALVE, DIAPHRAGM, 1” P.O.N.O.
VALVE, DIAPHRAGM, 4” P.O.N.O.
VALVE, BUTTERFLY, 3”
VALVE, BUTTERFLY, 6”
VALVE, BALL, CONTROL AIR, 1/4”
VALVE, BALL, PURGE ADJUST, 2”
VALVE, CHECK, PURGE, 2”
VALVE, CHECK, PURGE, 3”
VALVE, CHECK, FLOW, 4”
VALVE, CHECK, FLOW, 6”
VALVE, SAFETY/RELIEF 3/4”
VALVE, SOLENOID 24VDC MINI
VALVE, SOLENOID 24VDC MINI
QTY/
HL27001H00
AA
HL33001H00
AA
HL40001H00
AA
HL50001H00
AA
UNIT
705001-SP
NOTE 1
633653
705001-SP
NOTE 1
633653
705001-SP
NOTE 1
633653
705001-SP
NOTE 1
633653
1
NOTE 1
1
800030
800030
800030
800030
1
Refer to page 45 for Pilot Air Filter Element Section
38446357
38446357
38446357
38446357
23553357
23553357
23553357
23553357
631324
631324
631324
631324
680455
680455
680455
680455
634086
634086
634086
634086
633665-SP
633665-SP
633665-SP
633665-SP
683968
683968
683968
683968
725269-SP
725151-SP
725151-SP
725151-SP
633701
630622
630622
630721
630406
632170
632170
632170
632172
632172
632172
681621
681621
681621
681621
680466
680466
680466
680466
633943
633943
633943
634098
633364
633364
633364
633365
AD1415
AD1415
AD1415
AD1415
633658
633604
633604
633604
1
5
6
7
10
5
6
7
10
3
2
1
1
1
4
4
2
2
2
2
2
2
1
1
2
2
2
2
2
4
4
1
SPARES
2
3
1
5
6
7
10
5
6
7
10
1 1
5 5
6 6
7 7
10 10
5 5
6 6
7 7
10 10
2
2
2
1
1
1
NOTE 1: Refer to the Desiccant Fill Chart in the Maintenance section.
Spare. Quantities under this heading reflect the number of each item which we recommend be kept on hand for
maintenance or repair.
The appropriate quantity for your application will depend on how critical interruptions in service are to your operation.
Class
Quantity
Suggested for
1
2
3
Minimum
Average
Maximum
Domestic service where interruptions in service are acceptable.
Domestic service where some interruptions in service are acceptable.
Export service or for domestic service where interruptions in service are unacceptable.
44
HL Series Desiccant Dryer Models 90-5000
ingersollrandproducts.com
17.0 REPLACEMENT PARTS
DIAPHRAGM VALVE REBUILD KITS
VALVE DESCRIPTION
VALVE PART # *
SEAL KIT PART #
HARDWARE KIT PART #
VALVE, DIAPHRAGM, 3/4” P.O.N.C.
630569
630391
631762
VALVE, DIAPHRAGM, 1” P.O.N.C.
630575
630391
631762
VALVE, DIAPHRAGM, 1-1/2” P.O.N.C.
630572
630392
631763
VALVE, DIAPHRAGM, 2” P.O.N.C.
633701
633676
633702
VALVE, DIAPHRAGM, 1” P.O.N.O.
630721
630391
631757
VALVE, DIAPHRAGM, 1 1/2” P.O.N.O.
630725
630392
631758
VALVE, DIAPHRAGM, 2” P.O.N.O.
633667
633676
633677
VALVE, DIAPHRAGM, 3” P.O.N.O.
631478
630394
631760
VALVE, DIAPHRAGM, 4” P.O.N.O.
630406
630395
631761
NOTE: Refer to the list of individual parts at the beginning of the REPLACEMENT PARTS section to determine
which Valve listed in the above table is applicable to your dryer. PART #’s for the relevant Seal Kits and
Hardware Kits will be found in the adjacent columns.
EMS REPLACEMENT PARTS
DESCRIPTION
PART#
TRANSMITTER, DEWPOINT -40°F
633660
TRANSMITTER, DEWPOINT -100°F
633720
CABLE, TRANSMITTER
633671
BLOCK, SAMPLE -40°F
633661
BLOCK, SAMPLE -100°F
632823
BUTTERFLY VALVE PARTS AND REBUILD KITS
VALVE W/ ACT
VALVE
ONLY
VALVE REPAIR
KIT
ACTUATOR
ACTUATOR
KIT
VALVE, BUTTERFLY 3” W/ ACTUATOR
632170
633831
632685
632985
632686
VALVE, BUTTERFLY 6” W/ ACTUATOR
632172
633833
633834
633578
633579
VALVE DESCRIPTION
PILOT AIR FILTER REPLACEMENT ELEMENT
To determine the correct replacement element for the Pilot Air Filter, visually identify the filter that is mounted
on the right side of the Electrical Enclosure and compare it to the options shown below. Select the replacement
element that matches the Pilot Air Filter and use the corresponding Part Number when ordering
Use Replacement Element
Part Number: 85565513
Use Replacement Element
Part Number: 104424
HL Series Desiccant Dryer Models 90-5000
ingersollrandproducts.com
45
18.0 ENGINEERING SPECIFICATIONS
Inlet
Inlet Flow
Purge
Flow
-100
Flow
MODEL -40 DewDewpoint
(m3/h)
point
SCFM
SCFM
(cm)
Depth in. w/o
Bypass (cm)
Depth in. w/
Bypass (cm)
Air In
Shipping
& Out
Height in (cm)
Conne- Weight lbs (kg)
ction
Width in.
Desiccant
Weight per
Dryer (kg)
HL90
90
72
14
40.5 (102.9)
30 (76.2)
37.5 (95.3)
63.12 (160.3)
1
475 (213)
100 (45)
HL120
120
96
19
40.5 (102.9)
30 (76.2)
37.5 (95.3)
63.12 (160.3)
1
563 (255)
134 (61)
HL160
160
128
26
44.5 (113)
32 (81.3)
43.75 (111.1) 66.12 (167.9) 1 1/2
707 (321)
192 (87)
HL200
200
160
30
44.5 (113)
32 (81.3)
43.75 (111.1) 66.12 (167.9) 1 1/2
731 (332)
236 (107)
HL250
250
200
40
48.5 (123.2)
32 (81.3)
44.19 (112.2) 66.81 (169.7) 1 1/2
869 (394)
290 (132)
HL300
300
240
48
48.5 (123.2)
32 (81.3)
50.38 (128.0) 66.81 (169.7)
2
924 (419)
344 (156)
HL400
400
320
65
52.5 (133.4) 36.19 (91.9)
50.94 (129.4) 67.81 (172.2)
2
1115 (506)
470 (213)
HL500
500
400
81
56.5 (143.5) 39.69 (100.8)
54.5 (138.4)
82.5 (209.6)
2
1564 (709)
638 (289)
HL600
600
480
93
56.5 (143.5) 42.4 (107.8)
57.25 (145.4) 82.5 (209.6)
2
1664 (755)
748 (339)
HL800
800
640
130
64 (162.6)
51.25 (130.2) 64.38 (163.5) 87.62 (222.6)
3
2017 (915)
900 (408)
HL1000
1000
800
162
64 (162.6)
51.25 (130.2) 64.38 (163.5) 87.62 (222.6)
3
2237 (1015)
1100 (499)
HL1200
1200
960
195
64 (162.6)
51.25 (130.2) 64.38 (163.5) 87.62 (222.6)
3
2424 (1100)
1270 (576)
HL1500
1500
1200
243
78 (198.1)
54.76 (139.1)
N/A
80 (203.2)
4
2974 (1349)
1600 (726)
HL1800
1800
1440
292
84 (213.4)
60.62 (154.0)
N/A
91.88 (233.4)
4
3905 (1771)
2000 (907)
HL2100
2100
1680
340
84 (213.4)
60.62 (154.0)
N/A
91.88 (233.4)
4
4279 (1941)
2340 (1062)
HL2700
2700
2160
438
84 (213.4)
60.76 (154.3)
N/A
91.88 (233.4)
4
4926 (2234)
2928 (1328)
HL3300
3300
2640
535
96 (244)
66 (167.6)
N/A
100 (254)
6
2950 (1338) 3800 (1723) *
HL4000
4000
3200
649
96 (244)
66 (167.6)
N/A
100 (254)
6
3000 (1361) 4226 (1917) *
HL5000
5000
4000
811
102 (259)
72 (183)
N/A
92 (233.7)
6
3950 (1792) 5138 (2330) *
* Dryer weight shown does not include desiccant. Desiccant shipped separately.
Note: All above dryers rated at 150 psig, 120 °F max inlet temperature.
Capacity and purge flow is basis standard inlet conditions (100 psig / 100 °F) and will vary at different inlet
conditions.
NOTICE
Specification information above accurate at time of publication. Refer to equipment
serial label for actual specifications for units.
46
HL Series Desiccant Dryer Models 90-5000
ingersollrandproducts.com
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© 2012 Ingersoll-Rand, plc